Dodge MagnaGear Speed Reducers Size G525, Size G700, Size G920

Transcription

1 Dodge MagnaGear Speed Reducers Size G525, Size G700, Size G920 These instructions must be read thoroughly before installation or operation. GENERAL INFORMATION: The Dodge MagnaGear reducer is designed in accordance with the standards of the American Gear Manufacturers Association to give years of trouble-free operation. Unauthorized modifications are not allowed. In order to obtain good performance, there are precautions and procedures that must be observed when installing and servicing the reducer. This instruction manual contains installation, operating, and maintenance information for your reducer and its accessories. Additional information can be obtained by contacting your local DODGE sales office, distributor or authorized service center. INSTALLATION WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding. Remove all external loads from drive before removing or servicing drive or accessories. Failure to observe these precautions could result in bodily injury. INITIAL RECEIVING INSPECTION Carefully inspect the drive units for obvious outside damage. If any form of damage is present, notify the carrier and take photos for future use. Great care was taken to insure that the cargo was very well protected. Accessories such as heat exchangers, guards, and couplings may be packaged separately. Reducer Lifting Instructions If the reducer is not mounted on a base plate or swing base, the reducer may be lifted utilizing the four bolt holes located on top of the reducer at four corners. Use proper lifting equipment and safe lifting practices when lifting the reducer. The use of eye bolts and nylon straps are suggested to avoid damage to sheet metal or any painted surfaces. Metal lifting straps or cables can be used in place of nylon straps if needed. Foundation A foundation for mounting the reducer must be of sufficient size and rigidity to prevent movement when the MagnaGear unit is installed and operated, and to maintain the alignment between the driven equipment, the MagnaGear, and the drive motor. The foundation surface be flat and level to within /6 (.5 mm) to prevent distortion of the base plate or reducer when hold down bolts are tightened. A well laid concrete slab is the most effective way of ensuring a sound foundation. Steel sub bases can be used under the drive base. WARNING: Because of the possible danger to person(s) or property from accidents which may result from the improper use of products, it is important that correct procedures be followed. Products must be used in accordance with the engineering information specified in the catalog. Proper installation, maintenance and operation procedures must be observed. The instructions in the instruction manuals must be followed. Inspections should be made as necessary to assure safe operation under prevailing conditions. Proper guards and other suitable safety devices or procedures, as may be desirable, or as may be specified in safety codes should be provided, and are neither provided by Baldor Electric, nor are the responsibility of Baldor Electric. This unit and its associated equipment must be installed, adjusted and maintained by qualified personnel who are familiar with the construction and operation of all equipment in the system and the potential hazards involved. When risks to persons or property may be involved, a holding device must be an integral part of the driven equipment beyond the speed reducer output shaft. An elevated foundation will make oil drainage easier. The foundation must also have adequate strength and rigidity to withstand the operating forces resulting from the starting torque of the motor multiplied by the gear reduction ratio. Starting motor torque values can be three to even four times higher than nominal motor torque ratings. When the geardrive is directly attached to another component, i.e. shaft mounted on a pulley or an outboard bearing on the end of the reducer output shaft, one supporting structure shall be used to mount both components. Drive bases must be thermally stress relieved after fabrication for long term dimensional stability. It is preferred to have both the top and bottom surfaces machined flat to facilitate shimming. However, it is acceptable to have only the top mounting surfaces machined. Steel Foundations When mounting a reducer on structural steel, an engineered rigid baseplate is recommended. Fabricated pedestals or baseplates must be carefully designed to assure that they are sufficiently rigid to withstand operating conditions. DODGE MagnaGear motor baseplates are fabricated from heavy steel to achieve the necessary rigidity. Bolt the reducer and baseplate securely to the steel supports with proper shimming to ensure a flat and level surface. CAUTION: The reducer must be mounted on a flat base with proper shimming. Failure to observe this precaution could result in damage to or destruction of the equipment. Concrete Foundations If the reducer is to be mounted on a concrete foundation, grout steel mounting pads into the concrete base rather than grouting the reducer directly onto the concrete. If the reducer is mounted on a baseplate which will be installed on a concrete foundation, use the following instructions: The top of the foundation slab or steel sub base should be left to.5 (25 to 38 mm) lower than will finally be required to allow for grouting. When installing, the foundation should be roughened, cleaned, and dampened before placing the drive base in position. When installing the drive base on a steel sub base use epoxy type grout. When installing the drive base on a concrete foundation either epoxy type grout or non-shrinking Portland cement type of grout can be used.

2 Foundation bolts should be secured in the concrete as shown in Fig.. Allow adequate length for the bolts. Foundation bolts can be placed in the concrete at the time the concrete is poured. Foundation Bolt and Nut Drive Base Packing or Shims Concrete Figure Space for Grout Packing shims are placed between the top of the foundation and the baseplate until the unit is to.5 (25 to 38 mm) clear of the foundation. Adjust the packing or shims until a level placed on the baseplate indicates the base is level. After a preliminary alignment between the MagnaGear input and output couplings, the space between the top of the concrete surface and the bottom of the drive baseframe must be filled with grout. The grout should be thoroughly worked under the baseplate and be allowed to completely set (at least 72 hours). After the grout has set, the holding bolts should be tightened evenly. Final alignment of the MAGNAGEAR should be checked after the grout has set and the hold down bolts have been tightened. CAUTION: To move or lift a MagnaGear gearbox alone, use all 4 lifting holes in the corners of the upper housing. DO NOT use these holes to lift an entire drive motor-gearbox assembly. Use the lifting holes provided on the drive bases for lifting the drive assembly. ALIGNMENT AND LEVELING If the reducer was received mounted on a baseplate or swing base, the alignment must be checked prior to operation. The possibility of misalignment in transit may occur. Recheck alignment to determine if misalignment has occurred. Remove fan covers if necessary to provide access to foundation bolts. Replace cover after tightening bolts. Align the MagnaGear output shaft with the driven equipment shaft. The MagnaGear housing feet has tapped holes for leveling jackscrews. Start at the low speed end and work to the input side when leveling. If shims are used to level or align the unit or baseplate, they must be distributed uniformly around the base to support the entire mounting surface. The supported load must be equalized to avoid any distortion or localized stress on the lower housing. It is preferred to shim under the drive base for height adjustment. Use feeler gauges to determine the correct shim thickness needed to support each pad. All pads must be evenly supported when the reducer is secured. Use shims large enough to provide adequate support. If shims are not installed properly, they may get dislodged from their location which will cause severe misalignment in the system resulting in severe damage to all the components in the system. When low speed shaft alignment is complete, bolt down the reducer and tighten mounting fasteners to the torque values appropriate for the bolt sizes per Table. Align the motor coupling hub with the reducer input shaft hub CAUTION: The life of the MagnaGear reducer bearings is adversely affected by coupling misalignment. After both the high speed and low speed couplings have been aligned, tighten the motor hold down bolts to the torque values appropriate for the bolt sizes per Table. Recheck alignment. After alignment is completed, lubricate the couplings, if required, following the manufacturer s recommendations. Install high speed and low speed coupling guards in conformity with applicable safety standards for the location. MOTOR INPUT SHAFT COUPLING AND GUARD MAGNA REDUCER SHIMS BASE SHIMS Figure 2 - Typical HD Base Mounting SHIMS 2

3 Shaft Mounted Units Shaft mounted units require a torque arm. The connection between the gear unit and support must be flexible. The torque arm should be vertical and perpendicular to the gear drive or swingbase. Failure to follow these guidelines may result in damage to the gearbox or driven equipment. It may be beneficial to disengage the backstop when installing a shaft mounted gearbox by taking out the backstop attaching bolts. It is not necessary to remove the backstop. If the backstop is removed note the direction of the rotation arrow on the backstop, and reinstall the backstop with the proper freewheeling rotation after attaching the torque arm. SWING BASE LIFTING INSTRUCTIONS Lift the reducer assembly with nylon straps as shown. The use of wire rope or chain is not recommended due to the potential of damage. The nylon straps should not contact the motor housing or coupling guards due to potential sheet metal or paint damage. Note the alternate lifting point for lifting reducers with the optional electric fan kit installed. Metal lifting hooks can be used where nylon straps would be unsuitable. NYLON LIFTING STRAP NYLON LIFTING STRAP NYLON LIFTING STRAP NYLON LIFTING STRAP ALTERNATE LIFTING POINT FOR REDUCERS WITH ELECTRIC FANS CENTER OF GRAVITY LIFTING POINT Figure 3 - MagnaGear Lifting Points LIFTING POINT 3

4 SWING BASE INSTALLATION The swing base consists of a welded and machined steel structure which supports the reducer and motor assembly. There may be optional accessories mounted on the reducer such as a cooling fan, backstop, couplings, or heat exchanger. See Figure 4 for a typical swing base arrangement. To install the swing base to the driven equipment, use appropriate lifting equipment properly designed to safely lift the swing base into position. Attach and align the coupling mounted on the reducer/swing base assembly to the driven equipment coupling. Follow all recommendation of the coupling manufacturer and torque all bolts to the recommended specifications. Once the swing base is attached to the driven equipment, level the swing base so that it is horizontal. Attach the swing base rod assembly to the mounting position provided for on the swing base. Making sure that the rod assembly is perpendicular to the swing base, mount the mounting bracket to the appropriate surrounding structure. Make sure that the mounting structure is sufficient to support the reaction forces of the driven machine. If reducer was received mounted on a swing base, it was aligned at the factory. The possibility of misalignment in transit may occur and must be checked when mounting is complete. Recheck alignment to determine if misalignment has occurred. MAGNA REDUCER INPUT SHAFT COUPLING AND GUARD MOTOR TORQUE ARM ASSEMBLY Figure 4 - Typical Swing Base Mounting 4

5 COUPLING INSTALLATION Follow the installation instructions provided by the coupling manufacturer. Some general guidelines are provided that will aid in coupling installation. If the reducer is supplied with a backstop, do not connect couplings until the motor shaft direction of rotation is verified and is correct for the freewheeling rotation of the geardrive. Accurately measure the hub bore and shaft diameter to verify that each coupling hub and its shaft have an interference fit and that the amount of interference is adequate. Check the dimensions of the key on the shaft and on the coupling bore. Make sure the key is going to fit in the shaft and coupling keyways. Check the fit of the key in both the hub and shaft. The key should fit snugly against the sides of the keyway. A slight clearance should be present from top to bottom when the hub is on the shaft. Insert key flush with the end of the shaft. Check shaft, hub bore, and keys for nicks and burrs and remove as necessary. Use an oil bath to heat the coupling hubs to 245 F (8 C). Remove flexible elements before heating. Any kind of oil such as gear oil can be used as long as the flash temperature of the oil is high enough to avoid a fire hazard. Check the temperature of the coupling hub frequently with a Tempil-stick to avoid overheating. Alternatively mark the hub with a 275 F (35 C) temperature sensitive crayon (melts at prescribed temperatures) in several places on the hub. Remove flexible elements before heating. Use an oxy-acetylene or a blow torch to heat the hub. When using an oxy-acetylene torch use an excess acetylene mixture. Direct the flame toward the hub bore and keep it in motion while heating. Avoid over heating an area. WARNING: Do not use an open flame in a combustible atmosphere or near combustible materials. Mount the hub on the shaft as quickly as possible to avoid heat loss. Carefully line up bore and keyway with shaft and keyway and slide hub onto shaft until the shaft is at the right location relative to the shaft end. If it is necessary to drive hub into position, lightly tap with a soft brass or lead hammer. DO NOT USE excessive pounding which can cause damage to the bearings or gears. Allow coupling hub and shaft assembly to cool. SHEAVES AND SPROCKETS Mount sheaves and sprockets as close to the reducer as possible. Overtightening may cause damage to the reducer, belts or chain or driven equipment. Adjust chains to manufacturer s recommendations. Nominal Diameter (in) Table - Mounting Fastener Tightening Torques (coarse thread series): lb-ft Inch Fasteners Grade SAE 5 Nominal Diameter (mm) Metric Fasteners Class COUPLING ALIGNMENT Refer to the coupling manufacturer for the maximum recommended misalignment limits. Parallel or offset alignment is achieved by adding shims under the reducer and/or the drive base by moving the reducer and/or the drive base laterally as needed. A dial indicator gauge should be attached to the MagnaGear output coupling hub (low speed) and it should be positioned to contact the outside diameter of the pulley shaft or the outside diameter of the pulley coupling hub (Fig. 3). While slowly rotating the reducer shaft, the amount of eccentricity can be determined TIR (Total Indicator Reading) = 2 x P The difference in readings of the dial indicator gauge between any two locations 80 degrees apart will be double the amount of actual eccentricity. P 5 Figure 5

6 Angular alignment is achieved by measuring the gap between the ends of the two coupling hubs in both the horizontal and vertical planes (Fig. 4). TIR (Total Indicator Reading) = 2 x ( X - Y ) Figure 6 WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding. Remove all external loads from drive before removing or servicing drive or accessories. Failure to observe these precautions could result in bodily injury. Backstops The backstop is lubricated by the geardrive. There are no serviceable parts in the backstop assembly and no external lubrication is required. To change the direction of rotation on a geardrive equipped with a backstop, the backstop must be reversed to allow free rotation in the opposite direction. To change the direction of rotation, follow the procedure below. Y X 2. Clean and remove all RTV from the geardrive and backstop outer housing. 3. The inner race of the backstop is now visible and is held in place on the geardrive shaft by a snap ring. Remove the snap ring. Once the snap ring is removed, the inner race can be removed from the shaft. Do no use force, the inner race should be able to be removed from the shaft easily. Note the direction of the arrow stamped on the inner race. The direction of the arrow indicates the free direction of rotation. Turn the inner race end to end 80 degrees so the arrow is now reversed and slide the inner race back onto the shaft making sure the inner race lines up with the shaft key. Reinstall the snap ring. 4. Add a bead of RTV to the mating surface of the backstop outer housing making sure the RTV is added around each fastener hole. Do not apply excessive amounts of RTV to the backstop outer housing. 5. Before installing the backstop outer housing, the inner race sprags will need to be reset. To reset the sprags, a stiff two to three inch rubber band will be required. Stretch the rubber band around the sprags on the inner race. Once the backstop outer housing is piloted onto the inner race, cut and remove the rubber band. With a slight turning motion, slide the backstop outer housing into position. Do not force the backstop outer housing into position, if the outer housing is piloted correctly, it will slide easily into position. 6. Align the fastener holes in the backstop outer housing with the holes in the geardrive. Reinstall the previously removed bolts and tighten to the correct torque values given in Table. INSTALLATION OF ELECTRIC COOLING FAN Mount and align gearbox before installing electric fan kit. Remove the fan assembly and corresponding parts from the packing material. Verify and identify all of the components and fasteners shown on the graphic above. Sandwich the tabs located inside the fan shroud (qty. ) with the hex nuts (qty. 4) and flat washers (qty. 4) as shown in the graphic below.. Remove all bolts retaining the backstop outer housing to the geardrive. Remove backstop outer housing. To aid removal, lightly tap the backstop outer housing with a brass or plastic hammer to break the seal between the reducer and the backstop outer housing. Do not use a steel hammer. HEX BOLTS (QTY. 2) WASHERS (QTY. 2) FLAT WASHERS (QTY. 4) HEX NUTS (QTY. 4) SPACERS (QTY. 2) FAN SHROUD (QTY. ) ELECTRIC FAN ASSEMBLY (QTY. ) HEX BOLTS (QTY. 4) ADAPTER FITTING (QTY. ) PIPE TEE FITTING (QTY. ) REDUCER PIPE FITTING (QTY. ) TEMPERATURE SENSOR (QTY. ) HOUSING PLUGS (QTY. 2) SENSOR HOUSING (QTY. ) HEX NUTS (QTY. 4) FENDER WASHERS (QTY. 4) Figure 7 - Electric Cooling Fan Kit 6 HEX BOLTS (QTY. 4) FLAT WASHERS (QTY. 8) THREADED RODS (QTY. 4) HEX NUTS (QTY. 8) FLAT WASHERS (QTY. 4)

7 FENDER WASHER THREADED STUD HEX NUT WASHER TAB Figure 8 -- Fan Kit Center the electric fan (qty. ) with the clearance holes on the fan shroud (qty. ) mounting face using the flat washers (qty. 8), hex bolts (qty. 4), and hex nuts (qty. 4). Lay the spacers (qty. 2) over the two drilled and tapped mounting holes on the top surface of the gearbox. Bring the electric fan shroud with assembled electric fan and rest it on the spacers. Use the flat washers (qty. 2) and hex bolts (qty. 2) and reach through the clearance holes (on top of the fan shroud) and spacers to thread the bolts into the tapped holes (qty. ) then tighten the bolts. In the gearbox lower feet openings install the fender washers (qty. 2), flat washers (qty. 2), and hex nuts (qty. 2) to the foot side of the threaded studs. INSTALLATION OF (RTD) TEMPERATURE SENSOR fitting (qty. ), pipe tee fitting (qty. ), reducer pipe fitting (qty. ) temperature sensor (qty. ) housing plugs (qty. 2), and sensor housing (qty.) sealing each fitting with pipe sealant. Install the assembled components into the sump drain hole. Connect the RTD lead wires to the PLC. This is the device that signals the electric fan turning it off and on. The electric fan should operate when the sump temperature of the gearbox reaches 50 F. The resistance of the RTD at 50 F is Ω. WARNING: The user is responsible for conforming to the National Electrical Code and all other applicable local codes. Wiring practices, grounding disconnects and overcurrent protection are of particular importance. Failure to observe these precautions could result in severe bodily injury or loss of life. WIRING OF ELECTRIC FAN Use the attached electrical diagram below for wiring the electric motor. WARNING: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, and/or service this equipment. Read and understand this manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life. Verify that all of the fittings shown above have been supplied. Before adding lubrication to the gearbox remove the drain plug on the opposite side of the fan shroud. Assemble the adapter 7

8 LUBRICATION Mineral based EP oils are the preferred lubricant, suitable for operating temperatures up to 200 F (93 C) as well as for low ambient temperatures down to 25 F (-4 C). For lower temperatures or critical applications, synthetic lubricants which are suitable for operating temperatures up to 22 F (00 C) as well as for low ambient temperatures down to -5 F (-26 C). Fill to the level indicated by the dipstick or sight glass. External oil lines, pumps and heat exchangers will require additional quantities of oil. Run the gearmotor for 3 minutes to fill the heat exchanger and lube passages. Recheck the oil level and add oil as required. Approximate Oil Volume: Magna G525 Magna G700 Magna G gallons 26.4 gallons 35.8 gallons Refer to the reducer nameplate and use the dipstick to determine exact quantity of oil. Greased Shaft Seals Grease packed shaft seals must be re-greased depending on the contamination of the seal area. Under normal operating conditions re-grease the seals at every oil change. To re-grease the seals, remove the solid grease plug from the seal carrier and add fresh grease thru the zerk fitting provided while slowly rotating the reducer input shaft. Add enough grease to the seal carrier. Reinstall the solid grease plug in the seal carrier. Under extreme operating conditions, the seals should be re-greased every to 3 months depending on the severity of the operating conditions. DRAINING THE OIL Shut down the geardrive and follow lock out tag out procedures to prevent accidental startup. Refer to the figure 5 for the oil drain location. Completely drain or pump the oil into a suitable container. If it is suspected that the oil is contaminated, the geardrive should be flushed by pouring a charge of oil equal to the fill amount and allow the oil to drain into a container. Thoroughly clean the magnetic drain plugs. OIL SAMPLING A 25 micron filter is recommended to filter oil before it enters the gearbox. IMPORTANT: Because reducer is shipped without oil, it is necessary to add the proper amount of oil before operating reducer. Follow instructions on reducer warning tags and in the installation manual. Under average industrial operating conditions, the lubricant should be changed every 2500 hours of operation or every 6 months, whichever occurs first. Drain reducer and flush with kerosene, clean magnetic drain plugs and refill to proper level with new lubricant. CAUTION: Too much oil will cause overheating and too little will result in gear failure. Check oil level regularly. Failure to observe this precaution could result in bodily injury. Under extreme operating conditions, such as rapid rise and fall of temperature, dust, dirt, chemical particles, chemical fumes, or oil sump temperatures above 200 F, the oil should be changed every to 3 months, depending on severity of conditions. The performance of the new oil will be higher if a better job done in removing old oil from the reducer. A small amount of residual oil is usually not detrimental to performance. Never mix gear oils from different manufacturers or type. If changing oil brands or type, flush the geardrive by pouring a charge of the new oil into the gearbox and allow it to drain. Temperature Range 5 F to 60 F 50 F to 25 F Table 3 - Oil Recommendations - ISO Grades Output RPM Up to 00 Over EP 320EP 220EP 220EP Notes:. Assumes auxiliary cooling where recommended in the catalog. 2. Pour point of lubricant selected should be at least 0 F lower than expected minimum ambient starting temperature. 3. When properly selected for specific applications, MAGNAGEAR backstops are suitable for use with EP lubricants. 4. Special lubricants may be required for food and drug industry applications where contact with the product being manufactured may occur. Consult a lubrication manufacturer s representative for his recommendations. 5. For reducers operating in ambient temperatures between -22 F (-30 C) and 20 F ( 6.6 C) use a synthetic hydrocarbon lubricant, 00 ISO grade or AGMA 3 grade (for example, Mobil SHC627). Above 25 F (5 C), consult DODGE Gear Application Engineering (864) for lubrication recommendation. 6. Mobil SHC630 Series oil is recommended for high ambient temperatures. 8 Change oil per the schedule in Preventive Maintenance Section. It is a good idea to have the lubricant supplier perform an oil analysis at the time of oil change. Consider setting up an oil sampling plan to determine the optimal time to change the lubricant based on its condition. CAUTION: If your environment is especially high in moisture, dust and dirt, check the oil condition frequently. Take samples and check for condensation and sediment. Check the oil any time unusual ambient conditions might cause excessive condensation inside the gear case. CAUTION: If environmental conditions become severe with excessive amounts of dirt, dust or moisture, contact Dodge Product Support to determine whether other devices may be needed to protect your reducer. START UP General After the installation of the MagnaGear drive unit is completed, check the following to ensure safe operation of each MagnaGear drive.. Check the couplings connecting drive motor to MagnaGear for proper alignment. Check that the couplings are filled with the correct grade of grease as recommended by the coupling manufacture. 2. Check all mounting bolts, nuts and screws to be sure they are tight. 3. Check that oil is up to the correct level on the dipstick or in the oil level sight gauge. 4. Check direction of rotation of all components. 5. Ensure that the breather, access covers and coupling guards are in place and secured. Please note that breathers are shipped in a bag which is attached to the breather connection port. Remove the breather from the bag and screw it into the breather port. CAUTION: Do not operate unit with caps, covers or guards missing. 6. If equipped, operate the MagnaGear cooling pump to circulate lubricating/cooling oil through the system. Purge air from the pump housing volute by loosening plug at top portion of the volute. Check the oil level again to be sure oil is at the correct level with the pump running. 7. If the MagnaGear has an external backstop, check that the direction of rotation of the backstop and output drive shaft are the same. IMPORTANT: Lubricant level checks should be done with the cooling pump running, if equipped.

9 INSPECTION COVER INSPECTION COVER DIPSTICK BREATHER DIPSTICK BREATHER DRAIN HOLE DRAIN HOLE Right Angle Reducer Offset Parallel Reducer Figure 9 - Oil drain and dipstick / breather locations PREVENTIVE MAINTENANCE General All maintenance and repair work should be carried out by trained personnel. Perform the following maintenance at the recommended intervals. First day of operation Check oil temperature Sump temperature will vary based on operating conditions and cooling method. The gearbox is designed for a maximum oil sump temperature of 200 F (93 C). For water cooled heat exchangers, water flow rate can be adjusted to obtain the desired temperature. Flow rates in the higher range will reduce the oil sump temperature. Check with the cooler manufacturer to determine the allowable flow rates through the cooler. Check for change in noise level Check for oil leaks After first month or 600 hours of operation Check oil for water content Change oil Check mounting hardware for tightness Check for oil leaks Clean and reinstall the magnetic drain plugs Re-grease seals Periodically Check oil level Check for leakage Check oil temperature for changes Check for change in noise level Change oil filter Every 6 months or 2500 hours of operation Every 8 months or 8000 hours of operation for synthetic lubricant Check oil for water content Change oil Change oil filter Check mounting hardware for tightness Check for oil leaks Clean and reinstall the magnetic drain plugs Check the cooling system Oil Analysis Program Oil change intervals can be extended provided an oil analysis programs is in effect. General guidelines for typical properties and contaminate levels are listed below. If an oil sample indicates any of the conditions listed, the oil and filter should be changed. Viscosity Change: +/- 5% of starting ISO value Oxidation/TAN: Water: Iron: Silicon/Dirt: Copper: Aluminum: Increase of 2 in TAN over starting value 000 ppm 200 ppm 50 ppm 00 ppm 20 ppm Typically a 4: ratio of iron to silicon indicated dirt contamination. The values listed are guidelines. Trends are just as important as actual numbers. Increased contaminate values would indicate internal component wear is beginning to occur. The reducer should be monitored more frequently and may need to be removed from service for repair. Check oil for water content Change oil (Synthetic oil every 8 months or 8000 hours) Change oil filter with oil change Check mounting hardware for tightness Check for oil leaks Clean and reinstall the magnetic drain plugs Check the cooling system Re-grease seals 9

10 OIL VISCOSITY EQUIVALENCY CHART KINEMATIC VISCOSITIES cst/ cst/ 40 C 00 C ISO VG AGMA GRADES SAE GRADES GEAR OILS SAYBOLT VISCOSITIES SUS/ 00 F SUS/ 20 F A , W 80W 75W VISCOSITIES CAN BE RELATED HORIZONTALLY ONLY. VISCOSITIES BASED ON 96 VI SINGLE GRADE OILS. ISO ARE SPECIFIED AT 40 C. AGMA ARE SPECIFIED AT 40 C. SAE 75W, 80W, AND 85W SPECIFIED AT LOW TEMPERATURE. EQUIVALENT VISCOSITIES FOR 00 F AND 200 F ARE SHOWN. SAE 90 TO 250 SPECIFIED AT 00 C

11 GUIDELINES FOR MAGNAGEAR REDUCER LONG- TERM STORAGE During periods of long storage, or when waiting for delivery or installation of other equipment, special care should be taken to protect a gear reducer to have it ready to be in the best condition when placed into service. By taking special precautions, problems such as seal leakage and reducer failure due to lack of lubrication, improper lubrication quantity, or contamination can be avoided. The following precautions will protect gear reducers during periods of extended storage: Preparation:. Drain oil from the unit. Add a vapor phase corrosion inhibiting oil (VCI-05 oil by Daubert Chemical Co.) in accordance with Table Seal the unit airtight. Replace the vent plug with a standard pipe plug and wire the vent to the unit. 3. Cover all unpainted exterior parts with a waxy rust preventative compound that will keep oxygen away from the bare metal. (Non-Rust X-0 by Daubert Chemical Co. or equivalent) 4. The instruction manuals and lubrication tags are paper and must be kept dry. Either remove these documents and store them inside, or cover the unit with a durable waterproof cover which can keep moisture away. 5. Protect reducer from dust, moisture, and other contaminants by storing the unit in a dry area. 6. In damp environments, the reducer should be packed inside a moisture-proof container or an envelope of polyethylene containing a desiccant material. If the reducer is to be stored outdoors, cover the entire exterior with a rust preventative. When placing the reducer into service:. Fill the unit to the proper oil level using a recommended lubricant. The VCI oil will not affect the new lubricant. 2. Clean the shaft extensions with petroleum solvents. 3. Assemble the vent plug into the proper hole. 4. Follow the installation instructions provided in this manual. Table 4 Quantities of VCI #05 Oil (VCI #05 and #0 are interchangeable) Reducer Size Quantity (Ounces / Milliliter) G00 2 / 59 G50 3 / 89 G20 4 / 8 G285 6 / 77 G390 8 / 237 G525 8 / 237 G700 0 / 296 G920 2 / 355 Actual Ratios Nominal Ratio G525 Right Angle Reducer G525 Offset Parallel Reducer ACTUAL RATIO G700 Right Angle Reducer G700 Offset Parallel Reducer G920 Right Angle Reducer G920 Offset Parallel Reducer 8.00 N/A 8.82 N/A N/A N/A 9.33 N/A N/A N/A N/A 0.6 N/A N/A.499 N/A.460 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 49.9 N/A 50.9 N/A N/A N/A N/A N/A N/A N/A

12 REPLACEMENT OF PARTS IMPORTANT: Using tools normally found in a maintenance department, a Dodge MagnaGear speed reducer can be disassembled and reassembled by careful attention to the instructions following. Cleanliness is very important to prevent the introduction of dirt into the bearings and other parts of the reducer. A tank of clean solvent, an arbor press, and equipment for heating bearings and gears (for shrinking these parts on shafts) should be available. Our factory is prepared to repair reducers for customers who do not have proper facilities or who, for any reason, desire factory service. The oil seals are contact lip seals. Considerable care should be used during disassembly and reassembly to avoid damage to the surface on which the seals rub. The keyseat in the input shaft, as well as any sharp edges on the output hub should be covered with tape or paper before disassembly or reassembly. Also, be careful to remove any burrs or nicks on surfaces of the input shaft or output hub before disassembly or reassembly. Ordering Parts: When ordering parts for reducer, specify reducer size number, reducer model number, part name, part number, and quantity. It is strongly recommended that, when a pinion or gear is replaced, the mating pinion or gear is replaced also. If the large gear on the output shaft must be replaced, it is recommended that an output shaft assembly consisting of a gear assembled on a shaft be ordered to ensure undamaged surfaces on the output shaft where the output seals rub. However, if it is desired to use the old output shaft, press the gear and bearing off and examine the rubbing surface under the oil seal carefully for possible scratching or other damage resulting from the pressing operation. To prevent oil leakage at the shaft oil seals, the smooth surface of the output shaft must not be damaged. If any parts must be pressed from a shaft or from the output hub, this should be done before ordering parts to make sure that none of the bearings or other parts are damaged in removal. Do not press against the rollers or cage of any bearing. Because old shaft oil seals may be damaged in disassembly, it is advisable to order replacements for these parts. 2

13 Parts Reference for Magna G525 Right Angle Reducer Parts OUTBOARD BRG CONE SEE TABLE-A BRG. CUP HELICAL PINION OR SHELL PINION ASSEMBLY SEE TABLE-A BEVEL GEAR BEVEL GEAR KEY SEE TABLE-A SEE TABLE-A BEVEL GEAR SPACER SEE TABLE-A BEVEL PINION SEE TABLE-A USE RTV AT THESE JOINTS Brg. Cup Brg. Cone USE RTV AT THIS JOINT BRG. CONE PLUG TABBED SHIM SHIMS BRG. CUP HHCS SEE TABLE-A

14 Magna G525 Right Angle Shaft Reducer Parts Item Part # Description Quantity Cone LM54580 Cup LM Cone HH2240 Cup HH22449 Cone Cup /8 x 27 Grease Fitting #4 x 3/6 Rivet /8 SOC HD (Hex) Pipe Plug /4 SOC HD Pipe Plug Dry-Seal /4 NPT Socket HD Pipe Plug Dryseal Steel Per Ansi B Dipstick / Breather Combination 3/4 NPT ELESA L MagnaGear Nameplate Blank Reducer Sizes Planet Carrier Piece Design from Casting K Helical Pinion Cover Plate Low Head Shcs Grade 8.8, Din M2-.75 x 20 Long , Plain Housing - Monoblock Machining Input Seal Carrier Machining Input Housing Carrier Cover Plate Machining Right Angle Ouput Cover Machining Ouput Seal Carrier Machining Inspection Cover Gasket Spline Coupling LSS- Sun Pinion Sun Pinion Planet Gear Ring Gear Large HP Planetary Reducer Helical Gear Shaft Planet Spindle Helical Key Oil Pan Assembly (Bevel Gear) Tabbed Shim For Cup Input Carrier Shims Input Carrier Shims Input Carrier Shims Shims For Cub Shims For Cup Shims For Cup Output Cover Shims Output Cover Shims Output Cover Shims Cone Magna G525 Right Angle Shaft Reducer Parts, Continued Item Part # Desription Quantity Spherical Roller 2232 El Cup M2 x 2 Din. 95/ISO 4028 Dogpoint Set Screw (Steel, Min Hardness 45 HRC) HHCS Grade 8.8 Din 933, Plain M2-.75 x 35 Long _ Hardened Washer Din 696 (2 x 37 x HV) HHCS Grade 808 Din 933, Plain M6-2 x 45 Long HHCS Grade 0.9 DIN 93, Plain M x 50 Long Retaining Ring spring Steel DIN 472 Anderton Int. Circlip D A Lock-Nut Tan Lock-Washer TW 7 (For AN-7 Locknut) Dowel Pins Allow Steel.625 Diam x.75 Og Per ANSI B O-Ring Parker #2-273 Buna N or Equivalent O-Ring Parker #2-392 Buna N or Equivalent O-Ring Parker #2-208 Buna N or Equivalent O-Ring Cord Stock, Buna N or Equivalent Parker 3/6 (.20) Thick LGT O-Ring Parker #2-278 Buna N or Equivalent Lip Seal, Input Shaft Dual Lip HNBR Lip Seal, Input Shaft Single Lip HNBR Lip Seal, Output Shaft Dual Lip Seal HNBR Lip Seal, Output Shaft Single Lip Seal HNBR Speedi Sleeve CR # Speedi Sleeve CR # Right Angle Input Shaft Extension Key Output Shaft Extension Key O-Ring Parker #2-260 Viton or Equivalent TA Input Shims 2 70 Shim Int Pinion Thick (Quantities as needed) 2 7 Shim Int Pinion 0.05 Thick (Quantities as needed) 2 72 Tabbed Shim For Cup HH Thrust Washer 4

15 Overall Gearbox Ratio Table A for Magna G525 Right Angle Reducer Parts - Overall Gear Box Gear Ratios and Part Numbers Parallel IP Pinion Shaft Helical Gear Helical Shell Pinion Parallel IP Shell Pinion SFT Shell Pinion Key Shell Pinion SPCR Input Pinion Spacer Cone 8.: N/A N/A : N/A N/A N/A N/A N/A : N/A N/A N/A N/A N/A : N/A N/A N/A N/A N/A : N/A N/A N/A N/A N/A : N/A N/A N/A N/A N/A : N/A N/A N/A N/A N/A : N/A N/A N/A N/A : N/A N/A N/A N/A : N/A N/A N/A N/A : N/A N/A N/A N/A : N/A N/A N/A N/A Additional Backstop Parts for Magna G525 Right Angle Reducer Item Part # Description_I Quantity HHCS Grade 8.8 DIN 933, Plain M6-2 x 20 Long Helical Pinion Cover Plate Backstop Spacer Backstop Formsprag #RSC 00 (SPCL 85mm Bore) Shaft Key Backstop 20 mm x 2 mm x 80 mm Retaining Ring Anderton D DIN 47 5

16 Parts Reference for Magna G525 Parallel Shaft Reducer Parts 3 4 Parallel IP Pinion Standard D See Table-A 2 Input Pinion Spacer See Table-A Optional Backstop Assembly Parallel IP Pinion Backstop See Table-A 48 Bolt Torque for M20 x Grade is 340 lb-ft (460 Nm) Helical Gear

17 Parts Reference for Magna G525 Parallel Shaft Reducer Parts Item Part # Description Quantity HHCS Grade 8.8 Din 933, Plain MN6-2 x 20 Long Cone LM54580 Cup LM Cone HH2240 Cup HH22449 Cone Cup /8 x 27 Grease Fitting #4 x 3/6 Rivet /8 Soc HD (HEX) Pipe Lug /4 NPT Socket HD Pipe Plug Dryseal Steel Per ANSI B /4 NPT X 2 Nipple Per ASTM A /4 NPT Tee Fitting Per ASTM A Dipstick / Breather Combination 3/4 NPT ELESA L MagnaGear Nameplate Blank Reducer Sizes Pitot Tube Lubrigard #B4NT /4 - /4 NPT Hex Bushing Adapter /4 NPT Square HD Pipe Plug Per ASTM A Planet Carrier Piece Design from Casting Low Head SHCS Grade 8.8, Din M x 20 Long , Plain Housing - Monoblock Machining Carrier Cover Plate Machining Right Angle Output Cover Machining Output Seal Carrier Machining Inspection Cover Gasket Spline Coupling LSS - Sun Pinion Sun Pinion Planet Gear Ring Gear Large HP Planetary Reducer Input Cover Parallel Shaft Configuration End Cap Helical Pinion Shaft Helical Gear Shaft Planet Spindle Helical Key Tabbed Shim For Cup Shims For Cup Shims For Cup Shims For Cup Output Cover Shims Output Cover Shims Output Cover Shims Cone Parts Reference for Magna G525 Parallel Shaft Reducer Parts, continued Item Part # Description Quantity Spherical Roller 2232 EI Cup M2 x 2 Din. 95 / ISO 4028 Dogpoint Set Screw [Steel, Min Hardness 45 HRC] HHCS Grade 8.8 DIN 933, Plain M2-.75 x 35 Long _ Hardened Washer DIN 696 [ 2 x 37 x HV] HHCS Grade 8.8 DIN 933, Plain M Long HHCS Grade 0.9 DIN 93, M x 50 Long Retaining Ring Spring Steel DIN 472 Anderton Int. Circlip D300-30A Dowel Pins Alloy Steel.625 Diameter x.75 Lg Per ANSI B O-Ring Parker # Buna N or Equivalent O-Ring Cord Stock, Buna - N or Equivalent Parker 3/6 (.20) Thick x Lgt O-Ring Parker #2-278 Buna N or Equivalent Lip Seal, Output Shaft Dual Lip Seal Hnbr Lip Seal, Output Shaft Single Lip Seal Hnbr Speedi Sleeve CR # Speedi Sleeve CR # Output Shaft Extension Key Parallel Input Shaft Extension Key Spacer Ring Parallel IP Shaft Seal Carrier TA Input Shims 64 Shim Int Pinion Thick (Quantity as needed) 3 65 Shim Int Pinion 0.05 Thick (Quantity as needed) 3 66 Tabbed Shim For Cup HH Thrust Washer 7

18 Overall Gearbox Ratio Table A for Magna G525 Parallel Shaft Reducer Parts - Overall Gear Box Gear Ratios and Part Numbers Parallel IP Pinion Shaft Helical Gear Helical Shell Pinion Parallel IP Shell Pinion SFT Shell Pinion Key Shell Pinion SPCR Input Pinion Spacer Cone 8. : N/A N/A : N/A N/A N/A N/A N/A : N/A N/A N/A N/A N/A : N/A N/A N/A N/A N/A : N/A N/A N/A N/A N/A :3 : N/A N/A N/A N/A N/A : N/A N/A N/A N/A N/A : N/A N/A N/A N/A : N/A N/A N/A N/A : N/A N/A N/A N/A :65 : N/A N/A N/A N/A : N/A N/A N/A N/A Additional Backstop Parts for Magna G525 Parallel Shaft Reducer (Kit Part #453927) Item Part # Description_I Quantity HHCS Grade 8.8 DIN 933, Plain M6-2 x 20 Long Backstop Spacer Backstop Formsprag #RSC 00 (SPCL 85mm Bore) Shaft Key Backstop 20mm x 2mm x 80mm Retaining Ring Anderton D DIN 47 6 Shim Int Pinion Thick (Quantity as Needed) 7 Shim Int Pinion 0.05 Thick (Quantity as Needed) 8

19 Magna G700 Right Angle Reducer Parts IP PINION BACKSTOP SEE TABLE-A BEVEL PINION SEE TABLE-A IP PINION STANDARD SEE TABLE-A 2 C BEVEL GEAR SEE TABLE-A C C C INBOARD BRG CUP SEE TABLE-A INBOARD BRG SHIM & TAB SHIM SEE TABLE-A INBOARD BRG CONE SEE TABLE-A C BEVEL GEAR KEY SEE TABLE -A OUTBOARD BRG CONE SEE TABLE -A OUTBOARD BRG SHIM & TAB SHIM SEE TABLE -A OUTBOARD BRG CUP SEE TABLE -A BEARING CARRIER COVER PLATE SEE TABLE-A 64 HELICAL GEAR SEE TABLE-A

20 Magna G700 Right Angle Shaft Reducer Parts Item Part # Description Quantity HHCS Grade 8.8 DIN 933, Plain M2-.75 x 40 Long HHCS Grade 8.8 DIN 933, Plain M6-2 x 50 Long LM45349 Cone HH22449 Cone LM4530 Cup HH22430 Cup /8 x 27 Grease Fitting #4 x 3/6 Rivet /8 Soc HD (Hex) Pipe Plug /4 Soc HD Pipe Plug Dry-Seal /4 NPT Socket HD Pipe Plug Dry-Seal Steel Per ANSI B /4 NPT x 2 Nipple Per ASTM A Housing - Monoblock Machining Input Seal Carrier Machining Input Housing Output Cover Machining Output Seal Carrier Machining Spline Coupling LSS - Sun Pinion Sun Pinion Planet Gear Ring Gear Large HP Planetary Reducer Helical Gear Shaft Planet Spindle Spacer IST Stage Level Output Shaft Extension Key Helical Key Oil Pan Assembly (Bevel Gear) Input Carrier Shims Input Carrier Shims Input Carrier Shims Output Cover Shims (0.005 Thick) Output Cover Shims (0.007 Thick) Output Cover Shims (0.05 Thick) Spherical Roller 2233 E Assembly 32030X HHSC Grade 0.9 DIN 93, Plain M x 70 Long Retaining Ring Spring Steel DIN 472 Anderton Int. Circlip D Lock-Nut Tan Lock-Washer TW 20 (for Tan-20 Locknut) Right Angle Input Shaft Extension Key O-Ring Parker #2-264 Buna N or Equivalent O-Ring Parker #2-276 Buna N or Equivalent O-Ring Parker #2-393 Buna N or Equivalent 2 Magna G700 Right Angle Shaft Reducer Parts, continued Item Part # Description Quantity O-Ring Parker #2-279 Buna N or Equivalent Input Seal x x CRWHA Hnbr Dual Lip Input Seal x x CRWHA Hnbr Single Lip Lip Seal, Output Shaft 9.00 x 0.00 x Hnbr CRWH /4 NPT Tee Fitting Per ASTM A Planet Carrier Piece Design Dipstick / Breather Combination 3/4 NPT ELESA L MagnaGear Nameplate Blank Reducer Sizes Pitot Tube Lubrigard #B4NT /4 - /4 NPT Hex Bushing Adapter /4 NPT Square Head Pipe Plug Per ASTM A K & 920K Helical Pinion Cover Plate Low Head SHCS Grade 8.8, DIN 692, Plain M x 20 Long Inspection Cover Gasket M2 x 20 DIN 95 / ISO 4028 Dogpoint Setscrew (Steel, Min Hardness 45 HRC) Hardened Washer DIN 696, Plain (2 x 37 x HV) HHCS Grade 8.8 DIN 933, Plain M6-2 x 45 Long Dowel Pins Alloy Steel.625 Dia x.75 Lg Per ANSI B O-Ring Parker #2-208 Viton or Equivalent O-Ring Cord Stock, Buna N or Equivalent Parker 3/6 (.20) Thick x 92.5 Lgt Tabbed Shim For Cup HH Shims For Cup HH Shims For Cup HH Shims For Cup HH HH Cone Seal Wear Sleeve _ Thrust Washer HH2240 Cup O-Ring Parker #2-76 Viton or Equivalent 20

21 Table A for Magna G700 Right Angle Reducer Parts - Overall Gear Box Gear Ratios and Part Numbers Overall Gearbox Ratio Carrier Cover Plate Bevel Pinion Bevel Gear Bevel Gear Key IP Pinion Backstop IP Pinion Standard Helical Gear Cone Cup Inboard Cone Inboard Cup Shim Tab Shim Inboard Shim Inboard Tab Shim 2.4 : : : : : : : : : : : : : : : Additional Backstop Parts for Magna G700 Right Angle Reducer (Kit ) Item Part # Description_ Quantity Backstop Formsprag-RSCI 30 x 88mm Bore Key - Backstop 25 x 4 x Spacer Sleeve 90mm Bore High Ration Pinions 700K HHCS Grade 8.8 DIN 933, Plain M6-2 x 40 Long Retaining Ring Anderton #D DIN 47 2